---
title: The Cost of Frequent Color Changes
description: Learn how injection molders use purging compounds to reduce hot runner color-change scrap, improve changeover efficiency, and cut contamination during molding.
image: https://www.asaclean.com/hubfs/feeder-blender-device.jpg
---

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- Why Purge?
  
  
  
  ### Why Purge?
  
  Purging Compounds are an easy-to-use and affordable way to dramatically reduce scrap & downtime in plastics manufacturing. But how do you know if purging compounds are right for you?
  
  Learn why purging compounds are so important and see how Asaclean® helps your entire team succeed.
  
  Our Purging Experts answer frequently asked questions and address topics that benefit Process Technicians, Maintenance teams, Buyers, and even Plant Managers.
  
  [Learn more](https://www.asaclean.com/about-purging-compounds)
  
  
  
    - [Schedule a Free 10-Minute Consultation](https://offers.asaclean.com/free-purge-consultation)
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  #### Purging 101
  
  Our in-depth guide tells you everything you need to know about purging compounds. We want to give you the tools you need to make the best decision for your processing needs..
  
  [Explore our in-depth guide](https://www.asaclean.com/ultimate-guide-to-purge-compounds)
  
   
  
  
  
    - [ Why Purging Compounds? ](https://www.asaclean.com/en/about-purging-compounds)
    - [ Purging 101 ](https://www.asaclean.com/ultimate-guide-to-purge-compounds)
    - [ Cost Savings Calculator ](https://www.asaclean.com/cost-savings-calculator)
  
  
  [
  
  
  
  
  
  ![cost-savings-calculator-white](https://www.asaclean.com/hubfs/assets/images/ui/cost-savings-calculator-white.svg)
  
  ### Cost Savings Calculator
  
  Use our free calculator to see how much you will save with Asaclean® Purging Compounds.
  
   See the savings 
  
  
  
  ](https://www.asaclean.com/cost-savings-calculator)
- Cost Saving Solutions
  
  
  
  ### Cost Savings Solutions
  
  Our singular focus is saving your facility save time and money.
  
  Asaclean® helps injection molders, extruders, and blow molders dramatically reduce scrap and downtime.   
  Whether you’re struggling with hot runner color changeovers, costly screw pulls, or holding a bubble in blown-film extrusion, we have the solution to your problems.
  
  Asaclean® Purging Compounds are engineered to tackle your hardest processing challenges and make an incredible difference in your process efficiency.
  
  Here are some of the ways we can help you save:
  
  [Learn more](https://www.asaclean.com/solutions)
  
  
  
    - [Schedule a Free 10-Minute Consultation](https://offers.asaclean.com/free-purge-consultation)
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    - [ Color Changeovers & Contamination ](https://www.asaclean.com/solutions/color-changeovers)
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    - [ Black Specks/Carbon Contamination ](https://www.asaclean.com/solutions/carbon-contamination)
    - [ Preventative Purging ](https://www.asaclean.com/solutions/preventative-purging)
    - [ Screw Pulls ](https://www.asaclean.com/solutions/screw-pulls)
    - [ High & Low Temperature Changeovers ](https://www.asaclean.com/solutions/high-and-low-temp-changeovers)
    - [ Residue Issues/Clear Resins ](https://www.asaclean.com/solutions/residue-and-clear-resins)
    - [ Shutdown & Sealing ](https://www.asaclean.com/solutions/shutdown-and-sealing)
    - [ Customized Purge Programs ](https://www.asaclean.com/solutions/custom-purge-programs)
    - [ Free Purge Consultation ](https://offers.asaclean.com/free-purge-consultation)
  
  
  [
  
  
  
  
  
  ![cost-savings-calculator-white](https://www.asaclean.com/hubfs/assets/images/ui/cost-savings-calculator-white.svg)
  
  ### Cost Savings Calculator
  
  Use our free calculator to see how much you will save with Asaclean® Purging Compounds.
  
   See the savings 
  
  
  
  ](https://www.asaclean.com/cost-savings-calculator)
- Process & Industry
  
  
  
  ## Process and Industry
  
  With over 2,000 current customers and a combined 200+ years of processing experience, we’ve seen it all. Asaclean® understands your priorities and has excellent cost savings solutions specific to your process and industry.
  
  [Learn more](https://www.asaclean.com/process-industry)
  
  
  
    - <https://www.asaclean.com/blog/the-cost-of-frequent-color-changes#>[Schedule a Free 10-Minute Consultation](https://offers.asaclean.com/free-purge-consultation)
    - [Grade Selection Guide](https://www.asaclean.com/grade-selection-guide)
    - [Get a Free Sample](https://offers.asaclean.com/free-sample)
  
  
  
  
    - [ Industries ](https://www.asaclean.com/industry) 
          - [ Automotive ](https://www.asaclean.com/en/industry/automotive)
          - [ Custom Molders ](https://www.asaclean.com/industry/custom-molders)
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- [Purging Products ](https://www.asaclean.com/purging-products) 
    - [**Purging Products** ](https://www.asaclean.com/purging-products)
    - [ Mechanical Purging Compounds ](https://www.asaclean.com/purging-products/mechanical-purging-compounds)
    - [ Chemical Purging Compounds ](https://www.asaclean.com/purging-products/chemical-purging-compounds)
    - [ Purging Concentrates ](https://www.asaclean.com/purging-products/purge-concentrates)
- Resources
  
  
  
  ## Resources
  
  Learn how processors at over 2,000 manufacturing locations in North and South America use Asaclean® to cut scrap rates, reduce downtime, and transform their process efficiency.
  
  [See all resources](https://www.asaclean.com/resources)
  
  
  
    - [Cost Savings Calculator](https://www.asaclean.com/cost-savings-calculator)
    - [Schedule a Free 10-Minute Consultation](https://offers.asaclean.com/free-purge-consultation)
    - [Get a Free Sample](https://offers.asaclean.com/free-sample)
  
  
  
  
    - [ Customer Resources ](https://www.asaclean.com/resources#customer-resources) 
          - [ Purging Instructions ](https://www.asaclean.com/resources/purging-instructions)
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    - [ Other Resources ](https://www.asaclean.com/resources#other-resources) 
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          - [ Grade Selection Guide ](https://www.asaclean.com/grade-selection-guide)
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  [
  
  
  
  
  
  ![grade-selection-guide](https://www.asaclean.com/hubfs/assets/images/ui/white/grade-selection-guide.svg)
  
  ### Grade Selection Guide
  
  Use our Grade Selection Guide to receive personalized Asaclean® product recommendations based on your goals & processing information.
  
   Use the guide 
  
  
  
  ](https://www.asaclean.com/grade-selection-guide)
- [About Us ](https://www.asaclean.com/about-us) 
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 Injection Molding  / 4 min read  / June 09, 2026

# The Cost of Frequent Color Changes

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The Cost of Frequent Color Changes

4:50

Many custom molders run high-mix, low-volume production schedules that require constant changeovers.

One consumer-products molder in the southeastern United States was performing more than 20 color changes per week while processing approximately four million pounds of polypropylene annually. Despite using a purge program, the company continued to struggle with lengthy hot runner color changes and excessive scrap generation.

Their challenge is not unique.

Color changes become increasingly difficult when processors run:

- Pearlescent colors
- Dark pigments
- Highly loaded color concentrates
- Appearance-critical applications
- Multi-cavity hot runner molds

In many cases, residual color remains trapped near gates and low-flow regions, making complete cleaning difficult.

The result is more startup scrap and longer periods before acceptable parts are produced.

### Why Traditional Purging Approaches Often Fall Short

Many processors focus primarily on cleaning the screw and barrel during a changeover.

While this is important, it may not address contamination trapped inside the hot runner itself.

In some situations, molders continue cycling parts while waiting for old color to disappear. Others rely on extended flushing with production resin.

These approaches consume valuable machine time and often generate large amounts of scrap before stable production is achieved.

The challenge becomes even greater when processing teams need simple procedures that can be repeated consistently across multiple shifts and operators.

### A Different Approach to Hot Runner Purging

Hot runner systems often require a purge strategy specifically designed for low-flow areas and difficult-to-clean manifolds.

Rather than treating hot runner cleaning as an extension of barrel cleaning, successful processors focus on cleaning the entire melt path.

This includes:

- Screw and barrel
- Nozzle
- Manifold
- Gates
- Hot runner drops

Because contamination frequently remains trapped near gates, selecting a purge compound designed for hot runner applications can significantly improve results. Some purge technologies are specifically engineered to perform in these difficult-to-clean areas while leaving minimal residue behind.

### Real-World Results: Scrap Reduction of More Than 60%

The southeastern custom molder ultimately implemented a new hot runner purging strategy using a purging concentrate designed for challenging applications.

The results were dramatic.

Within two weeks, the company's hot runner scrap rate dropped from 5% to approximately 1.8%, representing a reduction of more than 62%. Color changes were completed in less than 15 minutes, allowing the team to spend more time producing good parts and less time generating waste.

Just as importantly, the process was simple enough to support a growing workforce without introducing additional complexity into production.

### What Injection Molders Can Learn from This Case

The biggest lesson is that not all contamination originates in the barrel.

When color changeovers continue taking longer than expected, the hot runner system itself may be the source of the problem.

Processors experiencing recurring color contamination, excessive startup scrap, or long changeovers should evaluate:

- Whether contamination remains trapped inside the hot runner
- If the purge strategy is designed for low-flow areas
- Whether operators are cleaning the entire melt path
- If the purge compound is suitable for hot runner applications

Addressing these factors can often produce substantial improvements in both quality and productivity.

### Conclusion

Hot runner systems are among the most difficult areas of an injection molding process to clean, which is why they frequently become a major source of scrap during color changes.

For processors running frequent changeovers, the costs can add up quickly through wasted resin, lost machine time, and extended startup periods.

By implementing a purge strategy specifically designed for hot runner systems, manufacturers can reduce contamination, shorten color changes, and significantly decrease scrap rates.

In many cases, improving hot runner cleaning is one of the fastest ways to improve overall molding efficiency.

A high-quality CPC should leave low residue to make for quick and efficient purging. Purging compound suppliers recommend different procedures for purging hot runners, and the method chosen depends largely on the resin(s) being processed, mold design and cleaning difficulty. If you have any questions, be sure to [consult your supplier](https://offers.asaclean.com/free-consultation).

**Learn how to reduce machine downtime with five quick purging compound tips for your injection molding application.**

****

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![Tom Hanvey](https://www.asaclean.com/hs-fs/hubfs/Tom%20Headshot.jpg?width=150&name=Tom%20Headshot.jpg)

#### [ Tom Hanvey ](https://www.asaclean.com/blog/author/tom-hanvey)

Tom Hanvey is the Associate Director of Marketing & Sustainability at Asahi Kasei Plastics North America. Before joining APNA, he worked as the Senior Marketing Manager for Asaclean Purging Compounds. He's worked in the plastics industry for over 10 years and focuses on recyclable resins and on the inbound marketing side, providing easy-to-digest content to processors looking for an edge on their competition.

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## Related Posts

[![](https://www.asaclean.com/hs-fs/hubfs/Injection%20Molding%20Stock.jpg?width=450&height=250&name=Injection%20Molding%20Stock.jpg)

How Custom Molders Can Achieve Faster Color Changes

 Troubleshooting  / 5 min read  / December 02, 2020 

](https://www.asaclean.com/blog/how-custom-molders-can-achieve-faster-color-changes)

[![](https://www.asaclean.com/hs-fs/hubfs/switching-purging-compounds.jpg?width=450&height=250&name=switching-purging-compounds.jpg)

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